Method and apparatus for implementing an unregulated dormant mode with an event counter in a power converter

ABSTRACT

A method for controlling an output of a power converter with a control circuit includes generating a drive signal to control switching of a switch to regulate the output of the power converter. It is detected if a switching period of one switching cycle of the drive signal exceeds a threshold switching period. The drive signal is disabled when a period of a switching cycle of the drive signal exceeds the threshold switching period for a threshold consecutive number of switching cycles.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/246,138, filed Aug. 24, 2016, now pending, which is a continuation ofU.S. patent application Ser. No. 14/535,730, filed Nov. 7, 2014, nowU.S. Pat. No. 9,484,822, which is a continuation of U.S. patentapplication Ser. No. 13/465,882, filed May 7, 2012, now U.S. Pat. No.8,908,395, which is a continuation of U.S. patent application Ser. No.13/170,018, filed Jun. 27, 2011, now U.S. Pat. No. 8,194,421, which is acontinuation of U.S. patent application Ser. No. 12/366,574, filed Feb.5, 2009, now U.S. Pat. No. 7,995,359. U.S. patent application Ser. No.15/246,138, and U.S. Pat. Nos. 9,484,822, 8,908,395; 8,194,421; and7,995,359 are hereby incorporated by reference.

This application is related to U.S. patent application Ser. No.12/129,474, filed May 29, 2008, now U.S. Pat. No. 7,952,895.

This application is also related to U.S. patent application Ser. No.12/961,241, filed Dec. 6, 2010, now U.S. Pat. No. 8,385,088.

BACKGROUND INFORMATION Field of the Disclosure

The present invention relates generally to control circuits thatregulate the delivery of energy in a switched mode power converter and,more specifically, the present invention relates to control circuitsthat reduce the energy consumption of switched mode power convertersunder light or no load conditions by use of an unregulated dormant modeof operation.

Background

Power converter control circuits may be used for a multitude of purposesand applications. There is a demand for control circuit functionalitythat can reduce the energy consumption of the power converter. Inparticular, there is specific demand for control circuits that reducethe energy consumption of power converters under conditions of light orno load. This demand comes from the fact that in some applications ofpower converters there is little or no requirement for energy deliveryat all for long periods of time. One example of such an application isin AC-DC chargers for cellular telephones. The AC-DC charger is oftenleft connected to the AC mains outlet in the home or office, even whenthe cellular phone itself is completely disconnected from the outputcable of the AC-DC charger. Such a condition is often referred to as ano-load condition. Furthermore in applications such as cellulartelephones and digital still cameras and the like, the unit beingpowered by the output of the AC-DC charger shuts down once the batteryinternal to the unit is fully charged. Under these conditions the energyrequirement of the unit falls dramatically and is therefore a very lightload condition for the AC-DC charger. This condition is often referredto as a standby or sleep mode and again can exist for long periods.There is therefore also demand for the AC-DC charger to operate withhigh efficiency or in other words with the lowest possible energyconsumption under these very light load standby or sleep modeconditions.

Existing control circuits for switched mode power converters typicallyreduce the energy consumption of the power converter by reducing theswitching frequency of a power switch coupled to the control circuit, toreduce a type of energy loss called switching losses. During this timeof reduced switching frequency, the control circuits remain active bymaintaining a power converter output voltage such that the unit to bepowered (the cellular telephone handset or digital still camera forexample) can receive energy as soon as it is connected to the AC-DCcharger output or as soon as it comes out of sleep/standby mode anddemands more energy.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention aredescribed with reference to the following figures, wherein likereference numerals refer to like parts throughout the various viewsunless otherwise specified.

FIG. 1 is a schematic illustrating generally an example flyback powerconverter employing an example of a control circuit that reduces theenergy consumption of the power converter under light or no loadconditions by use of an unregulated dormant mode of operation inaccordance with the teachings of the present invention.

FIG. 2 is a schematic illustrating another example flyback powerconverter employing another example of a control circuit that reducesthe energy consumption of the power converter under light or no loadconditions by use of an unregulated dormant mode of operation inaccordance with the teachings of the present invention.

FIG. 3 is a schematic illustrating yet another example flyback powerconverter employing yet another example of a control circuit thatreduces the energy consumption of the power converter under light or noload conditions by use of an unregulated dormant mode of operation inaccordance with the teachings of the present invention.

FIG. 4A is an example block diagram of a control circuit that reducesthe energy consumption of a power converter under light or no loadconditions in accordance with the teachings of the present invention.

FIG. 4B shows example timing and signal waveforms that in one exampleare from a control circuit with the block diagram of FIG. 4A

FIGS. 5A and 5B shows example waveforms that in one example are from acontrol circuit with the block diagram of FIG. 4A.

FIG. 6 is a schematic illustrating still another example flyback powerconverter employing still another example of a control circuit thatreduces the energy consumption of the power converter under light or noload conditions by use of an unregulated dormant mode of operation inaccordance with the teachings of the present invention.

FIG. 7 is a graph showing typical switching frequency versus loadcharacteristics of various control circuits that reduce the energyconsumption of power converters under light or no load conditions.

FIG. 8 is a graph showing an example control characteristic of a controlcircuit that reduces the energy consumption of a power converter underlight or no load conditions in accordance with the teachings of thepresent invention

FIG. 9 is a flowchart illustrating an example method for reducing theenergy consumption of a power converter under light or no loadconditions by use of an unregulated dormant mode of operation inaccordance with the teachings of the present invention.

DETAILED DESCRIPTION

Methods and apparatuses for implementing a control circuit for reducingthe energy consumption of a power converter under light or no loadconditions by use of an unregulated dormant mode of operation aredisclosed. In the following description, numerous specific details areset forth in order to provide a thorough understanding of the presentinvention. It will be apparent, however, to one having ordinary skill inthe art that the specific detail need not be employed to practice thepresent invention. In other instances, well-known materials or methodshave not been described in detail in order to avoid obscuring thepresent invention.

Reference throughout this specification to “one embodiment”, “anembodiment”, “one example” or “an example” means that a particularfeature, structure or characteristic described in connection with theembodiment or example is included in at least one embodiment of thepresent invention. Thus, appearances of the phrases “in one embodiment”,“in an embodiment”, “one example” or “an example” in various placesthroughout this specification are not necessarily all referring to thesame embodiment or example. Furthermore, the particular features,structures or characteristics may be combined in any suitablecombinations and/or subcombinations in one or more embodiments orexamples. In addition, it is appreciated that the figures providedherewith are for explanation purposes to persons ordinarily skilled inthe art and that the drawings are not necessarily drawn to scale.

A control circuit for reducing the energy consumption of a powerconverter under light or no load conditions by use of an unregulateddormant mode of operation will now be described. Examples of the presentinvention involve methods and apparatuses to implement an unregulateddormant mode of operation to reduce the energy consumption of a powerconverter under light or no load conditions. The following descriptionwill detail a number of example control circuits used in a variety ofpower converter circuits that regulate energy flow from an input of thepower converter to the output of the power converter under normaloperating conditions, which could be for example when a cellulartelephone is connected to the output of the power converter and ischarging its battery. The flow of energy from input to the output of thepower converter can also be described in terms of energy flow through anenergy transfer element, which may include a transformer within thepower converter but could be a simple inductor in some power converterconfigurations. The description will detail how the example controlcircuits described transition to a mode of operation where energy flowfrom input to output of the power converter is no longer regulated whenthe output of the power converter is identified as being in a no-load orvery light load condition, for example when the cellular telephone isphysically disconnected from the output of the AC-DC charger in whichthe control circuit is used. Under these conditions, the transfer ofenergy from input to output of the power converter is substantiallyreduced to zero for a period of time that is programmed by the user ofthe control circuit or is preprogrammed using a timer circuit inside thecontrol circuit itself. During this period of time the circuit is in theunregulated dormant mode of operation referred to in the title of thisdisclosure. During this unregulated dormant mode time period, the powerconsumption of the control circuit itself is reduced as much as possibleto conserve energy. The description will detail how, after thisunregulated dormant mode period of operation, the control circuit willrestart and again regulate energy flow from the input of the powerconverter to the output of the power converter. If however the verylight load or no-load condition is still present, the control circuitwill again detect this and again initiate a period of unregulateddormant mode operation.

To illustrate, FIG. 1 shows generally a schematic of a power converter100, also sometimes referred to as a power supply, employing a controlcircuit 115 that regulates energy flow through the energy transferelement 109. In the illustrated example, control circuit 115 includes anunregulated dormant mode control circuit 140 employed to reduce theenergy consumption of the power converter 100 under light or no loadconditions by use of an unregulated dormant mode of operation inaccordance with the teachings of the present invention. In one example,power converter 100 is an isolated flyback converter where primaryground 107 and secondary return 126 are electrically isolated from oneanother. It is noted that in other examples power converter 100 could benon-isolated with primary ground 107 and secondary return 126electrically connected together in accordance with the teachings of thepresent invention. Other non-isolated power converter configurationsthat could benefit from the teachings of the present invention couldfurther include buck, CUK or SEPIC converters. It is further noted thatin other examples, power converter 100 could have more than one outputin accordance with the teachings of the present invention.

As shown in the illustrated example, a control circuit 115 includes adrive signal generator block 154, which generates a drive signal 122that is to be coupled to drive a power switch 105. In one example, powerswitch 105 is a metal oxide semiconductor field effect transistor(MOSFET), a bipolar transistor or the like. Power switch 105 is coupledto the input winding 103 of energy transfer element 109, which iscoupled to a DC input voltage 101 and an output power diode 117. In oneexample, DC input voltage 101 is the output of a rectifier circuitcoupled to a source of AC voltage not shown. Capacitor 106 is coupled topower converter input terminals 190 and 191 to provide a low impedancesource for switching currents flowing through first and second inputterminals 190 and 191, energy transfer element 109 winding 103 and powerswitch 105 when the power switch 105 is in an ON state. In one example,control circuit 115 and switch 105 could form part of an integratedcircuit that could be manufactured as a hybrid or monolithic integratedcircuit. As shown in the depicted example, control circuit 115 iscoupled to receive a feedback signal 114, which in one example is avoltage signal, but in other examples could also be a current signal, orother signal representative of a parameter of the power converter 100output, while still benefiting from the teachings of the presentinvention.

When power converter 100 is first connected to the input voltage supply101 in the illustrated example, control circuit 115 derives start upcurrent to initiate operation of the control circuit. This is achievedby charging up an external bypass capacitor 133 coupled to bypassterminal 170. In the example of FIG. 1 this start up current is derivedfrom the high voltage connection node 134 of power switch 105 andcoupled to a regulator circuit 135 internal to control circuit 115. Anoutput 132 from regulator circuit 135 is coupled to an external bypasscapacitor 133 and is also the voltage supply rail for the circuitryinternal to control circuit 115. In another example, the connection node134 could instead be coupled to input terminal 190 or to a node internalto the structure of power switch 105 in the case that power switch 105and control circuit 115 are integrated on a single die and/orincorporated within a single semiconductor package.

In the illustrated example, regulator circuit 135 converts the highvoltage present on node 134, which in one example is typically in therange of 50 to 400V relative to primary ground 107, and regulates themaximum voltage on rail 132 to a lower voltage, which can be used tooperate the control circuit 100. Initially the voltage across bypasscapacitor 133 is substantially zero and the regulator circuit 135provides current to charge up bypass capacitor 133. When the voltage onbypass capacitor 133 is sufficient for correct operation of controlcircuit 115, which in one example is typically in the order of 6 Volts,an internal under-voltage circuit, not shown, enables control circuit115 to start operation, which initiates switching of power switch 105with drive signal 122. This, in turn, initiates the flow of energy frominput terminals 190 and 191 through energy transfer element 109.

Energy transfer element 109 includes input winding 103 and outputwinding 110 and a low voltage (which in one example is typically in therange 10 to 30V) auxiliary winding 108. The feedback signal 114 iscoupled to control circuit 115 from auxiliary winding 108 through theresistor divider formed by resistors 111 and 112. In addition, whenauxiliary winding capacitor 175 is sufficiently charged, the controlcircuit 115 receives the supply current 180 for the control circuit 115to operate through resistor 171. In the illustrated example, derivingcurrent from the low voltage auxiliary winding 108 in this way is moreefficient than regulator circuit 135 deriving current from the highvoltage node 134. As such, the operation of regulator circuit block 135is typically disabled when supply current Icc 180 is available throughresistor 171.

In one example, control circuit 115 includes a drive signal generator154 to generate a drive signal 122, which is to be coupled to drivepower switch 105 to regulate energy flow through energy transfer element109 by regulating the frequency at which power switch 105 is switched onand off in response to the feedback signal 114. This switching frequencyregulation can be achieved in a number of ways including varying thefrequency of an oscillator, not shown, within control circuit 115,selectively enabling and disabling switching cycles of power switch 105derived from a fixed frequency oscillator within control circuit 115(often to referred to as on/off control) varying an off time of thepower switch 105 with a fixed on time of power switch 105 or varying anon time of the power switch 105 with a fixed off time of power switch105. When switch 105 is on, energy from the capacitor 106 is transferredinto the input winding 103 of the energy transfer element 109. When theswitch is off, the energy stored in the input winding 103 is transferredto the output winding 110 and to auxiliary winding 108. The energy fromoutput winding 110 is transferred to the output of the power supply 100with a current that flows through a forward biased output power diode117 to capacitor 118, a load 121 coupled to preload impedance 194 andthe output terminals 192 and 193. Since, in this example, switchingfrequency is the variable used to regulate energy flow, the frequency atwhich the power switch 105 is switching is therefore a measure of thetotal energy flowing through energy transfer element 109.

In the example of FIG. 1, control circuit 115 is coupled to regulate thetotal energy delivered from the first and second input terminals 190 and191 of power converter 100 through energy transfer element 109 to thepower converter output terminals 192 and 193, the preload impedance 194,the control circuit supply terminal 170 and the feedback components 111and 112 in addition to the feedback terminal 123. In an example cellulartelephone charger providing a full load output power to load 121 of 3Watts (an energy of 3 Joules per second), the energy consumed by thepreload 194, control circuit 115 supply current 180 and feedback current131 is typically less than 1% of the energy consumed by load 121. In oneexample preload 194 is removed altogether. However, if output loadcurrent 120 is substantially eliminated by either physicallydisconnecting load 121 or when load 121 is in a standby mode ofoperation, the combined energy consumption of the preload 194 ifpresent, control circuit 115 supply current 180 and feedback current 131can become substantially 100% of the energy flowing through energytransfer element 109.

Since, as described above, in the example of FIG. 1, switching frequencyof power switch 105 is the variable used to regulate energy flow throughenergy transfer element 109, the switching frequency is therefore anindication of the total energy requirement or demand of the circuitrycoupled to the windings 108 and 110 of energy transfer element 109.Therefore, in the illustrated example, when the switching frequency ofpower switch 105 falls below a threshold value, it is used as anindication that output current 120 has been reduced to substantiallyzero and that a no-load or very light load condition therefore existswhere load 121 is requiring substantially no energy. In other words,when the energy requirements of load 121 falls below a threshold value ano-load or very light load condition has been identified.

Under these conditions, control circuit 115 in one example includesunregulated dormant mode control circuit 140, which, if the energyrequirements of load 121 have fallen below a threshold value for longerthan a threshold period of time, is coupled to generate a powerdown/reset signal 157 coupled to render dormant the drive signalgenerator 154 by powering down the drive signal generator 154 for aperiod of time. During this period of time while the drive signalgenerator 154 is powered down, the drive signal generator 154 no longergenerates drive signal 122 and no longer regulates the energy flowthrough the energy transfer element 109. In one example, the duration ofthe period of time for which drive signal generator 154 is powered downand the switching of power switch 105 is disabled is determined by thelength of time it takes for bypass capacitor 133 to discharge from itsnormal operating voltage, which in one example is in the range of 5.8 to6.4 Volts, down to a lower voltage, which in one example could be 3Volts. During this time, output capacitor 118 also discharges throughpreload impedance 194 and output voltage 119 also therefore falls. Thus,in this example, bypass capacitor 133 also functions as part of a timerto determine a time period in response to the indication that outputcurrent 120 has been reduced to substantially zero and that a no-load orvery light load condition therefore exists. During this time, capacitor175 also discharges through resistors 171 and 111 and the voltage acrosscapacitor 175 also therefore falls. It is appreciated that in anotherexample, the duration of the period of time for which drive signalgenerator 154 is powered down and the switching of power switch 105 isdisabled could be determined by a timer circuit comprising a capacitorexternal to control circuit 115 but which is not the bypass capacitor133. In a further example, the duration of the period of time for whichdrive signal generator 154 is powered down and the switching of powerswitch 105 is disabled could be determined by a timer circuit which isentirely integrated within control circuit 115 with no need for anexternal capacitor for this purpose.

In order to reduce the energy consumption of the control circuit as muchas possible during this time period, internal regulator circuit block135 is also powered down in response to the power down/reset signal 157such that substantially no current flows from node 134 through regulatorcircuit 135 and the energy consumed by regulator circuit block 135 issubstantially zero. During this unregulated dormant mode time periodwhere the drive signal generator 154 of control circuit 115 ceases toregulate energy flow through energy transfer element 109, controlcircuit 115 is unresponsive to feedback signals received at terminal 123until the unregulated dormant mode time period has elapsed. During thisunregulated dormant mode period, therefore, in addition to powering downregulator circuit block 135, substantially all other circuitry insidecontrol circuit 115 is also powered down and disconnected from supplyrail 132 in response to power down/reset signal 157. This disconnectionresults in reduced power consumption and can be achieved using simplesemiconductor load switches as will be known to one of ordinary skill inthe art.

In one example an unregulated dormant mode time period is only initiatedwhen the energy requirements of load 121 have fallen below a thresholdvalue for longer than a threshold period of time, so that short termtransient energy requirement conditions or events are not misinterpretedas no load conditions at the output of the power converter 100. In oneexample such a load transient event could be caused by a sudden changefrom full charging of a cellphone battery coupled to the output of powerconverter 100 as load 121, to trickle charging of the cellphone battery.This type of load transient often occurs in cellphone chargingapplications and can be followed very quickly by a sudden increase inload as the cellphone handset reverts back to full charging. Such loador energy requirement transients are controlled by the load 121 and aretherefore changes of load 121 energy requirements to which the controlcircuit 115 must respond correctly. If the control circuit 115immediately responded to a sudden reduction in load energy requirement,the control circuit 115 could have entered into an unregulated dormantmode period when the load again demanded increased energy which is not adesirable condition since in one example this could affect the speedwith which a battery load is charged. By ensuring that the unregulateddormant mode time period is only initiated when the energy requirementsof load 121 have fallen below a threshold value for longer than athreshold period of time, the risk of misinterpreting transient loadevents is reduced.

As will be discussed in greater detail below with reference to FIG. 4A,a circuit block that remains powered up in control circuit 115 is aportion of the unregulated dormant mode control circuit 140, which inone example includes an internal power up circuit block that detectswhen the voltage across bypass capacitor 133 falls to the 3V lowerthreshold. Thus, in the illustrated example, the unregulated dormantmode time period is considered to have elapsed when the voltage acrossbypass capacitor 133 falls to the 3V lower threshold, at which point thepower up circuit block provides an internal reset signal inside theunregulated dormant mode control circuit 140 that resets the powerdown/reset signal 157 and reinitiates the control circuit 115 start upoperation to power up the circuitry as described above with regard towhen the input voltage supply 101 was first connected.

Therefore, in the illustrated example, bypass capacitor 133 is rechargedwhen the control circuit 115 start up operation is reinitiated inresponse to the power down/reset signal 157. The bypass capacitor 133 isrecharged using current flowing through regulator circuit 135 and whenthe voltage across bypass capacitor 133 again exceeds the under-voltagethreshold voltage required for correct operation of the control circuit115, which in one example is approximately 6V, drive signal generator154 is powered up and drive signal 122 is generated to resume theswitching of power switch 105. At this point, drive signal generator 154is again responsive to feedback signals received at terminal 123 andenergy again flows through energy transfer element 109 to replenishenergy lost in capacitors 175 and 118. The switching frequency of powerswitch 105 will be high during this time. However, after the energy incapacitors 175 and 118 is replenished, if the load 121 still requiressubstantially no energy, the switching frequency will again fall belowthe threshold value and if this condition exists for longer than athreshold period of time, will again cause the power down/reset signal157 to initiate a power down, which will again cause the drive signalgenerator 154 in control circuit 115 to cease the regulation of energyflow through energy transfer element 109 as described above. Thisoperation of powering down and going dormant for a period of time,followed by a start up and resumed switching period, will repeatcontinuously until the energy requirement of load 121 again increasessuch that the switching frequency of power switch is maintained abovethe threshold value and the control circuit 115 then regulates the flowof energy through energy transfer element continuously according to theenergy required by the total load on energy transfer element windings108 and 110.

It is appreciated that in other examples of control circuit 115,following a period of unregulated dormant mode operation, the internalreset signal inside unregulated dormant mode control circuit 140 couldinitiate a low power restart sequence which consumes less energy thanthe normal start up when input voltage supply 101 is first connected.For instance, in one example, a low power restart sequence could includerecharging bypass capacitor 133 to a value above the under-voltagethreshold with current flowing through regulator circuit 135 as above.However, when switching of power switch 105 is resumed, output capacitor118 could be partially recharged only enough to simply detect whether itis being discharged at a rate that indicates that a no-load condition atthe output of power converter 100 still exists, in which case theunregulated dormant mode operating period would then be repeated. It isappreciated that this low power restart functionality would offer evenfurther reduction in energy consumption, but could result in addedcomplexity or cost to the overall power converter. The additional costor complexity would result from the addition of circuitry to controlcircuit 115 to remember the fact that it had previously been in a lowpower unregulated mode of operation and also circuitry to detect adischarge rate of output capacitor 118, or some other way of detectingoutput current, at voltage conditions below the normal regulated valueof output voltage 119.

It is noted that FIG. 1 shows that auxiliary winding 108 is anon-isolated winding of energy transfer element 109. Thus, it isappreciated therefore that the benefits of the teachings of the presentinvention may be applied to power converters that include energytransfer elements with isolated windings, non-isolated windings andcombinations thereof. Examples of non-isolated windings includenon-isolated sense windings, non-isolated bias windings, non-isolatedoutput windings and the like. It is also noted that one or more loadsmay be coupled to the various windings of the energy transfer element inaccordance with the teachings of the present invention. Indeed, FIG. 1shows that both preload impedance 194 and load 121 are coupled to outputwinding 110 in the illustrated example. It is appreciated therefore thecombinations of different one or more loads may be coupled to thedifferent combinations of the windings of an energy transfer elementresulting in many different load and winding configurations that mayenjoy the benefits of a power converter including an unregulated dormantmode of operation in accordance with the teachings of the presentinvention.

For instance, in an example in which energy transfer element 109includes a non-isolated sense winding, one of the one or more loads maybe coupled to the non-isolated sense winding. In another example, one ofthe one or more loads may be coupled to an isolated output winding whileanother one of the one or more loads may be coupled to the non-isolatedsense winding. In an example that includes a non-isolated bias winding,one or more of the loads may be coupled to the non-isolated biaswinding. In another example, one of the one or more loads may be coupledto an isolated output winding while another one of the one or more loadsmay be coupled to the non-isolated bias winding. In an example in whichthe energy transfer element includes a non-isolated output winding, oneof the one or more loads may be a combined sensing and bias load that iscoupled to the non-isolated output winding. In an example in which theenergy transfer element includes an isolated output winding and anon-isolated output winding, one of the one or more loads may be coupledto the isolated output winding and another one of the one or more loadsmay be a load that includes a combined sensing and bias load coupled tothe non-isolated output winding.

FIG. 2 shows another example power converter circuit 200 using a controlcircuit 215 benefiting from the teachings of the present invention. Thefunctionality of the power converter circuit example shares many aspectsof the power converter circuit example described in FIG. 1. A differencecompared to the circuit of FIG. 1 is that the resistor 171 is eliminatedsuch that the operating current of control circuit 215 under normaloperating conditions is derived entirely through regulator circuit 235.Energy transfer element winding 208 is therefore only used as a sensewinding providing a feedback voltage across capacitor 275 whichgenerates a feedback current I_(FB) 231. However, the operation when theenergy required by load 221 falls below a threshold value for more thana threshold period of time, which in one example is detected by theswitching frequency of power switch 205 falling below a threshold valuefor more than a threshold period of time, is identical to that of thecircuit of FIG. 1. Under those circumstances, an unregulated dormantmode of operation is initiated where regulator circuit 235 is disabledand substantially all circuit blocks other than a portion of theunregulated dormant mode control circuit 240 are disconnected fromsupply rail 232 while the voltage at external bypass capacitor 233discharges from its normal operating voltage to the power up thresholdvoltage detected by unregulated dormant mode control circuit 240. In theexample, the bypass capacitor 233 is then recharged to its normaloperating voltage level, which in one example is approximately 6 Volts,and switching of power switch 205 is restarted.

FIG. 3 shows another example power converter circuit 300 using a controlcircuit 315 benefiting from the teachings of the present invention. Thefunctionality of the example power converter 300 illustrated in FIG. 3shares many aspects of the power converter circuit described in FIG. 2.A difference compared to the power converter circuit 200 of FIG. 2 isthat the diode 213 and capacitor 275 are eliminated. In common with thepower converter circuit 200 of FIG. 2, therefore, is that the operatingcurrent of control circuit 315 under normal operating conditions isderived through regulator circuit 335. Furthermore winding 308 of energytransfer element provides an AC voltage at node 313 relative to primaryground potential node 307. As a result, the feedback current I_(FB) 331has both positive and negative values during a switching cycle of thepower switch 305. I_(FB) 331 is a negative current during substantiallyall of the on time of power switch 305 and is a positive current for atleast a portion of the off time of power switch 305. However, theoperation when the energy required by load 321 falls below a thresholdvalue for more than a threshold period of time, which in one example isdetected by the switching frequency of power switch 305 falling below athreshold value for a predetermined period of time, is similar to thatof the example power converter circuits of FIG. 1 and FIG. 2. Underthose circumstances, an unregulated dormant mode of operation isinitiated, where in one example, regulator circuit 335 is disabled andsubstantially all circuit blocks in control circuit 315 other than aportion of the unregulated dormant mode control circuit 340 aredisconnected from supply rail 332 while the external bypass capacitor333 voltage discharges from its normal operating voltage to a power upthreshold voltage detected by unregulated dormant mode control circuit340. The bypass capacitor 333 is then recharged to its normal operatingvoltage level, which in one example is approximately 5.8 Volts, andswitching of power switch 305 is restarted.

FIG. 4A shows an example simplified block diagram 400 of a portion of acontrol circuit 415 that could be applied to any of the example controlcircuits 115, 215 or 315 in accordance with the teachings of the presentinvention. FIG. 4A still shows more details than control circuit blockdiagrams 115, 215 and 315 but remains a simplified diagram intended toshow only the level of detail necessary for the description of thepresent invention. As such certain functional connections between thevarious internal circuit blocks, that would be visible in a detailedcontrol circuit 415 block diagram, are not shown so as not to obscurethe teachings of the present invention.

As described with reference to FIG. 1 above, the example configurationshown in FIG. 4A uses a high voltage node 434 coupled to a node internalto the structure of power switch 405. The example configuration of FIG.4A is therefore one where the control circuit 415 and power switch 405could be monolithically integrated on a single silicon die where thisinternal node of power switch 405 is available. As shown in the depictedexample, node 434 is coupled to regulation circuit 435, which can havesimilar functionality to blocks 135, 235 and 335 as shown in FIGS. 1, 2and/or 3, and is shown coupled to receive a power down/reset signal 457from unregulated dormant mode control circuit 440. It is appreciatedthat although the combined power down/reset signal 457 is illustrated asa single connection in FIG. 4A, the power down and reset signals ofpower down/reset signal 457 could also be separate electrical signalswith separate electrical connections in another example.

In the example of FIG. 4A, control circuit 415 includes a drive signalgenerator 454, which in the example is illustrated as including anon/off control circuit. In the illustrated example, the on/off controlcircuit of drive signal generator 454 is coupled to receive an EN signal456 output from the FB block 451. The FB block 451 is coupled to receivea feedback signal at FB terminal 423. In the illustrated example, the FBblock 451 generates the output EN signal 456 as low when no switching ofpower switch 405 is required but as high when switching of power switch405 is required. In other examples, FB terminal 423 and FB block 451could be adapted to receive and process a DC or AC feedback signaldepending on the external circuit configurations as discussed withreference to FIGS. 1, 2 and/or 3 above.

As shown in FIG. 4A, one example of the unregulated dormant mode controlcircuit 440 of control circuit 415 includes a power down (PD) detectionblock 458, event counter 498, power up (PU) detection block 442 andlatch circuit 459 coupled as shown. When the energy requirement of theone or more loads coupled to the energy transfer element at the outputof a power converter, such as for example loads 121, 221 and 331 inFIGS. 1, 2 and 3, respectively, falls below a threshold value, theinternal EN signal 456 will stay low for more than 128 cycles ofoscillator 452. In the illustrated example, PD detection block 458includes a 7-bit counter, which functions as a divide-by-128 circuit. Itis appreciated that in other examples the PD detection block 458 couldbe designed to act as a divide-by circuit for a range of 50-250oscillator cycles. Accordingly, if the 7-bit counter of PD detectionblock 458 of the unregulated dormant mode control circuit 440 does notreceive a high EN signal 456 for 128 oscillator cycles, the PD detectionblock 458 outputs a pulse 461 with a logic high state which clocks aninput to event counter circuit block 498 and increments a counterinternal to block 498 by 1. The PD detection block 458 is then resetwhen the drive signal 422 again goes high indicating that the feedbacksignal at FB terminal 423 is indicating more energy is required by aload or loads coupled to the energy transfer element at the output of apower converter. EN signal 456 therefore goes high and drive signal 422in turn goes high. In the example, drive signal 422 is also coupled toevent counter block 498. In one example if drive signal 422 goes highmore than once within the 128 oscillator counts, the event counter 498is also reset as this indicates that any prior reduction in energyrequirement sufficient to generate a logic high pulse from PD detectionblock 458, was a transient event and gate drive signals are now beinggenerated again with the drive signal 422 being low for less than 128oscillator 452 cycles. If however only one drive signal 422 pulse isreceived by event counter block 498 within 128 oscillator 452 counts,the event counter is not reset. If the 7-bit counter of PD detectionblock 458 of the unregulated dormant mode control circuit 440 again doesnot receive a high EN signal 456 for 128 oscillator cycles, the PDdetection block 458 again outputs a pulse 461 with a logic high statewhich is used as an input to event counter circuit block 498 andincrements a counter internal to block 498 by another 1. If the eventcounter block 498 counter reaches a count of n, which in one example is4, block 498 outputs a logic high signal 497 and triggers the latchcircuit 459 to send the power down/reset signal 457 to most of theinternal circuit blocks of control circuit 415. In the illustratedexample, these blocks are coupled to receive the power down/reset signal457 include feedback circuit block 451, oscillator circuit block 452,over current detect circuit block 453, which detects the current flowingthrough power switch 405, drive signal generator block 454 and the 7 bitcounter 458. In one example, when all these blocks are powered down inresponse to the power down/reset signal 457, the controller 415 consumesa current, I_(cc) 480, of only 2 to 5 μA.

In one example therefore, a time period of unregulated dormant modeoperation is initiated when the event counter 498 counts n consecutiveevents for which the time between drive signal 422 logic high statesexceed 128 oscillator 452 cycles. It is appreciated that the value of128 oscillator cycles could be modified to any number of oscillatorcycles or any time period measured through means other than theoscillator 452.

FIG. 4B shows waveforms that in one example could be generated withinthe block diagram of FIG. 4A. FIG. 4B illustrates one example of asequence of gate drive pulses 462, which in one example could be thesame as drive signal 422 in FIG. 4A, and the count of the PD counter463, which in one example could be the count within block 458 in FIG.4A, and the event count 464, which in one example could be the countwithin block 498 in FIG. 4A. The sequence starts at time point 468 wherethe event counter count 463 is 0. In the example, label 473 is thenumber of oscillator counts recorded during the indicated period of timebetween times 468 and 471. Fewer that 128 oscillator counts are recordedin PD counter count 463 before the next gate drive signal 462 isreceived at time point 471. The PD count is therefore reset at time 471and the event counter count 464 remains 0. However at time point 472,128 oscillator cycles have been received and the event counter count 464is incremented. It is appreciated that in another example, the eventcounter could be incremented at the time when the next gate drive signal497 high pulse is received. Similarly, in the example, when the gatedrive signal is received at time point 465, PD counter count 463 hasagain counted 128 oscillator cycles at time point 466, and thereforeevent counter count 464 is again incremented at time point 466. At timepoint 467 however another gate drive signal is received with PD countercount at <128. In the example therefore, both PD counter count 463 andevent counter count 464 are reset at time point 467. In the example ofFIG. 4B, between time point 467 and time point 469, there are 4consecutive gate drive signals that are separated by more than 128oscillator cycles and the even counter count therefore reaches a valueof 4. In the example, the event counter threshold value of n in FIG. 4Ais 4. Consequently, at time point 469 a power down or unregulateddormant mode operation period is initiated.

Since regulator circuit 435 is turned off in response to the powerdown/reset signal 457, external bypass capacitor 433 is no longercharged through regulator circuit 435, bypass capacitor 433 will beginto discharge and the bypass voltage 450 will start to drop. In theillustrated example, the bypass voltage 450 will drop from approximately6 volts to an internally set PU detection voltage of approximately 3volts. As shown in the example, PU detection block 442 remains coupledto detect the bypass voltage 450 and remains active (as well as latchcircuit 459) during the unregulated dormant mode. In one example, PUdetection block 442 includes a comparator coupled to bypass capacitor433 to determine when the bypass voltage 450 has fallen to the 3 volt PUthreshold. When the bypass voltage 450 has dropped to the 3 volt PUthreshold, the PU reset signal 441 output from PU detection block 440goes high, which causes power down/reset signal 457 from latch circuit459 to go high and causes regulator circuit 435 to resume charging thebypass capacitor 433.

In one example, some or all of the other internal circuit blocks ofcontroller circuit 415 may also resume functioning as bypass capacitor433 is recharged. The bypass capacitor 433 will be charged up toapproximately 6 volts and again the PD detection block 458 will start tosense if a high EN signal 456 is present at least once every 128oscillator cycles, and if not, the PD detection block 458 will againcause output signal 461 from 7-bit counter 458 to generate a logic pulseand initiate a count within event counter block 498, which, if the countreaches a count of n, will retrigger the latch circuit 459 to cause anew shut down cycle to start.

As mentioned above, it is noted that in the specific example illustratedin FIG. 4A, a control circuit 415 that utilizes an on/off control schemeto regulate the flow of energy through the energy element coupled to thepower switch is shown for explanation purposes. It is appreciated thatcontrol circuit 415 may utilize other known control schemes to regulatethe flow of energy and detect no load or light load conditions in orderto benefit from an unregulated dormant mode operation in accordance withthe teachings of the present invention.

For instance, in another example, a magnitude of the feedback signalcould be sensed by FB block 451 to detect the no load or light loadcondition. In such an example, the magnitude of the feedback signalcould be a voltage value or a current value. In this example, when FBblock 451 detects a magnitude of the feedback signal received atfeedback terminal 423 that indicates a no load or light load condition,FB block 451 will output a signal 456 to PD detection block to indicatethe no load or light load condition. In yet another example, a no loador light load condition may be detected by detecting a low switchingfrequency of the drive signal 422. In one example, the switchingfrequency of the drive signal 422 may be detected through the FB block451, which is coupled to receive the feedback signal. In such anexample, the switching frequency of the drive signal 422 may be derivedfrom the feedback signal received at feedback terminal 423. In anotherexample, PD detection block 458 could be coupled to receive the drivesignal 422 to detect the low switching frequency condition of drivesignal 422 to detect the no load or light load condition.

FIGS. 5A and 5B show example voltage waveforms, which in one exampleapply to the bypass voltage 450 at bypass capacitor 433 of FIG. 4Adescribed above. FIG. 5B shows a waveform 501 that is an expanded viewof region 502 from waveform 500 of FIG. 5A. In the example, the timesshown in FIGS. 5A and 5B assume a bypass capacitor 433 value of 10 μF,an oscillator 452 frequency of 100 kHz and a current consumption (I_(cc)480) of 2 μA during the unregulated dormant mode period 503. In additionit is assumed that regulator circuit 435 charges bypass capacitor 433with 2 mA when recharging bypass capacitor 433 from 3 to 6 V duringperiod 504. Period 505 is of an undetermined value ‘x’ millisecondssince this is the period taken to recharge the output capacitor, such asfor example capacitor 118, 218 or 318 and other capacitance coupled toauxiliary energy transfer element windings, such as for examplecapacitors 175 and 275. Period 505 is therefore a function of the choiceof these capacitors, but in typical examples could be in the range of5-20 milliseconds. Period 506 is the time it takes the 100 kHzoscillator to count through 128 cycles and then increment an eventcounter n times, where in the example n=4, before again recognizing inthe example shown, that the energy requirement of the load is below athreshold value and has been for a period of time 506 and the controlcircuit again starts a period of unregulated dormant mode operation inaccordance with the teachings of the present invention. It isappreciated that in one example, as described with respect to FIG. 4A,time period 506 is made up of a series of n events where consecutivedrive signal 422 high/low events are separated by periods of time inexcess of 128 oscillator cycles.

FIG. 6 shows another example power converter 600 benefiting from theteachings of the present invention. As shown, the example circuit ofFIG. 6 shares many aspects with those of FIGS. 1, 2 and/or 3 discussedabove. A difference, however, includes that the circuit of FIG. 6employs an optocoupler 611 and secondary feedback circuit block 694 togenerate a feedback signal 639. In the example case of control circuit615, current 631 is a combined feedback current and supply current tothe control circuit 615 as used for example by the TOPSwitch family ofintegrated circuits manufactured by Power Integrations, Inc., of SanJose, Calif.

In the example of control circuit 615, therefore, the value of externalbypass capacitor 633 determines the unregulated dormant mode timeperiod. The variable used to detect when the energy required by the loadcircuit 621 has fallen below a threshold value to initiate theunregulated dormant mode of operation can also be the switchingfrequency of the power switch 605. However, in the example of controlcircuit 615, the magnitude of the feedback signal, such as the I_(C) 631feedback signal can also be used to detect when the energy required bythe load circuit 621 has fallen below a threshold value to initiate theunregulated dormant mode of operation, as will be discussed withreference to FIG. 8. The magnitude of the feedback signal could be thecurrent value of the I_(C) 631 current, or in another example, themagnitude could be a voltage value responsive to the I_(C) 631 current.

FIG. 7 shows a few example load versus switching frequencycharacteristics of control circuits that could benefit from the exampleteachings of the present invention. Characteristic 703 is typical ofsimple on/off control or variable frequency control schemes discussedearlier, where load and switching frequency are linearly related.Examples of control circuits using this type of control scheme are TinySwitch, LinkSwitch-LP, LinkSwitch-TN and LinkSwitch-XT, all manufacturedby Power Integrations, Inc., of San Jose, Calif.

In the case of example characteristic 703, operation in the lightload/no-load condition 712 region can for example be detected when theswitching frequency falls below threshold value 707 indicating that theload has fallen below threshold value 708. Characteristic 704 is typicalof an on/off control circuit with multiple power switch over currentthreshold levels and a state machine to determine which over currentthreshold to use in each load condition. Examples of control circuitsusing this type of control scheme are TinySwitch-II, TinySwitch-III,PeakSwitch and LinkSwitch-II, all of which are manufactured by PowerIntegrations, Inc., of San Jose, Calif. Characteristic 705 is typical ofa PWM control circuit characteristic where operation in high loadcondition 710 and/or medium load condition 711 is typically with fixedaverage switching frequency 713, but where average switching frequencyis reduced in the light and no-load region 712. Examples of controlcircuits using this type of control scheme are TOPSwitch-FX andTOPSwitch-GX, both of which are manufactured by Power Integrations,Inc., of San Jose, Calif. Characteristic 706 is typical of a PWM controlcircuit with more complex control schemes where operation in high loadcondition 710 and a portion of medium load condition 711 is typicallywith fixed average switching frequency 714, but where the averageswitching frequency is reduced in other portions of medium loadcondition 711 and light load/no-load condition 712 regions. An exampleof a control circuit using this type of control scheme is TOPSwitch-HXmanufactured by Power Integrations, Inc., of San Jose, Calif.

Regardless of the control scheme used, a common factor is that switchingfrequency is reduced at light load/no-load conditions and can thereforebe used as a way to detect a light or no-load condition on the output ofa power converter. This is true of numerous other control circuits usingthese or other light load operating schemes, such as burst mode, wherethe average switching frequency is also reduced under light load/no-loadconditions.

FIG. 8 shows an example of a duty cycle 801 versus I_(C) 802 currentcharacteristic, which in one example could apply to the circuitconfiguration described above with reference to FIG. 6. The examplecharacteristic of FIG. 8 illustrates that the detection of a lightload/no-load condition is not limited to detecting a switching frequencyof a power switch. As shown in the example characteristic of FIG. 8, areduction in load on the output of the power converter is indicated byan increase in Ic 802 current as indicated by label 804. Detection of athreshold Ic current 805, where the duty cycle falls to substantiallyzero, in combination with an event counter or timer can therefore beused as an indication that the energy requirements of a load at theoutput of the power converter have fallen below a threshold value for aperiod of time and could therefore be used to initiate a period ofunregulated dormant mode operation in accordance with the teachings ofthe present invention. It is appreciated that with other controlschemes, there are other ways that may be employed to indicate a lightload/no-load condition and used therefore to initiate an unregulateddormant mode of operation in accordance with the teachings of thepresent invention.

FIG. 9 shows generally a flowchart 900 describing one example method ofimplementing an unregulated dormant mode of operation in a powerconverter in accordance with the present invention. As shown in theexample, the power converter starts up in block 901 and energy isdelivered to the load in block 902. In block 903, feedback informationis received regarding the energy requirement of the load and in block904, it is decided whether the energy requirement of the load is below athreshold value, which would indicate a light load/no-load condition. Ifnot, energy delivery is regulated in block 905 and again feedbackinformation is received in block 903. If however, in block 904 it isdecided that the energy requirement of the load is below a thresholdvalue, which would indicate a light load/no-load condition, in block910, it is determined whether this condition has existed for longer thana predetermined period of time. If it has, in block 906 regulation ofenergy delivery is ceased, and in block 907 a time period of unregulateddormant mode is started. In either blocks 906 or 907, unnecessarycircuit blocks are powered down so as to reduce energy consumptionduring the time period of unregulated dormant mode. In block 908 it isdecided whether the time period of unregulated dormant mode is complete.When it is, the power converter is restarted in block 909 and thenreturns to block 902 where energy is delivered to the load. It isappreciated that in one example, block 909 could be eliminated if a YESdecision in block 908 was connected directly to block 901 where theinitial start up of the power converter is undertaken. However, thepresence of block 909 allows for a different start up mode when theperiod of unregulated dormant mode operation is complete which couldinclude for example starting up in a lower energy consumption state thanthe normal start up of the power supply in order to check for thepresence of a light or no-load condition without all of the controlcircuit blocks being active for example and therefore reducing energyconsumption even further. If in block 904, the energy requirement of theload is not below a threshold value or if in block 910, the condition ofthe energy requirement of the load being below a threshold value has notexited for longer than a threshold period of time, energy delivery tothe load is again regulated in block 905 and information regarding theenergy requirement of the load is again received in block 903.

The above description of illustrated examples of the present invention,including what is described in the Abstract, are not intended to beexhaustive or to be limitation to the precise forms disclosed. Whilespecific embodiments of, and examples for, the invention are describedherein for illustrative purposes, various equivalent modifications arepossible without departing from the broader spirit and scope of thepresent invention. Indeed, it is appreciated that the specific voltages,currents, frequencies, power range values, times, etc., are provided forexplanation purposes and that other values may also be employed in otherembodiments and examples in accordance with the teachings of the presentinvention.

These modifications can be made to examples of the invention in light ofthe above detailed description. The terms used in the following claimsshould not be construed to limit the invention to the specificembodiments disclosed in the specification and the claims. Rather, thescope is to be determined entirely by the following claims, which are tobe construed in accordance with established doctrines of claiminterpretation. The present specification and figures are accordingly tobe regarded as illustrative rather than restrictive.

What is claimed is:
 1. A method for controlling an output of a powerconverter with a control circuit, the method comprising: generating adrive signal to control switching of a switch to regulate the output ofthe power converter; detecting if a switching period of one switchingcycle of the drive signal exceeds a threshold switching period; anddisabling the drive signal when a period of a switching cycle of thedrive signal exceeds the threshold switching period for a thresholdconsecutive number of switching cycles.
 2. The method of claim 1,wherein the drive signal is unresponsive to the output of the powerconverter in response to said disabling the drive signal.
 3. The methodof claim 1, wherein said generating the drive signal to controlswitching of the switch comprises generating the drive signal in avariable frequency control scheme such that a load coupled to the outputof the power converter and the switching frequency are linearly related.4. The method of claim 1, wherein said generating the drive signal tocontrol switching of the switch comprises generating the drive signal inan on/off control scheme such that a load coupled to the output of thepower converter and the switching frequency are linearly related.
 5. Themethod of claim 1, further comprising powering up a drive signalgenerator coupled to generate the drive signal in response to disablingthe drive signal for a first time period.
 6. The method of claim 5,wherein said powering up the drive signal generator is responsive anexternal timer coupled to a terminal.
 7. The method of claim 5, whereinthe drive signal is unresponsive to changes in an energy requirement ofthe load coupled to the output of the power converter when the drivesignal is disabled, and wherein the drive signal is responsive tochanges in the energy requirement of the load coupled to the output ofthe power converter after the first time period has elapsed.
 8. Themethod circuit of claim 1, wherein said detecting if the switchingperiod of one switching cycle of the drive signal exceeds the thresholdswitching period comprises receiving an oscillating signal from anoscillator to detect if the switching period of one switching cycle ofthe drive signal exceeds the threshold switching period.
 9. The methodof claim 8, wherein said detecting if the switching period of oneswitching cycle of the drive signal exceeds the threshold switchingperiod further comprises: counting with a first counter cycles of theoscillating signal to detect if the switching period of one switchingcycle of the drive signal exceeds the threshold switching period; andcounting with a second counter a number of times that a threshold numberof oscillating signal cycles are counted.
 10. The method of claim 9,further comprising resetting the first counter in response to anoccurrence of a drive signal pulse prior to the first counter countingthe threshold number of oscillator cycles.
 11. The method of claim 9,further comprising resetting the second counter in response to anoccurrence of a drive signal pulse prior to the first counter countingthe threshold number of oscillator cycles.
 12. A method for reducingenergy consumption of a power converter with a control circuit, themethod comprising: generating a drive signal to control switching of aswitch to regulate an output of the power converter; operating in aburst switching mode responsive to the output of the power converter,wherein the burst switching mode includes a switching state in whichswitching is enabled and a non-switching state in which switching isdisabled; detecting if a length of a non-switching state of the burstswitching mode is longer than a threshold time period; and rendering thecontrol circuit dormant if the length of the non-switching state of theburst switching mode is longer than the threshold time period for athreshold consecutive number of times.
 13. The method of claim 12,further comprising operating in the burst switching mode in light loadand no-load conditions for a load coupled to the output of the powerconverter.
 14. The method of claim 12, wherein the drive signal isunresponsive to the output of the power converter when the controlcircuit is dormant.
 15. The method of claim 12, further comprisingpowering up a drive signal generator coupled to generate the drivesignal after control circuit has been rendered dormant for a first timeperiod.
 16. The method of claim 15, further comprising determining thefirst time period in response to an external timer coupled to aterminal.
 17. The method of claim 15, wherein the drive signal isunresponsive to changes in an energy requirement of the load coupled tothe output of the power converter when the drive signal is disabled, andwherein the drive signal is responsive to changes in the energyrequirement of the load coupled to the output of the power converterafter the first time period has elapsed.
 18. A method for controlling apower converter with a control circuit having a dormant mode, the methodcomprising: generating a drive signal having a switching period for eachswitching cycle comprising an on-time and an off-time, the drive signalto control switching of a power switch to regulate an output of thepower converter, wherein the drive signal may have a non-constantswitching period; detecting if the switching period for a switchingcycle exceeds a threshold switching period; and placing the controlcircuit in a reduced energy consumption state if the switching periodfor the switching cycle exceeds a threshold switching period for athreshold consecutive number of times.
 19. The method of claim 18,wherein the threshold consecutive number of times is greater than two.20. The method of claim 18, wherein the drive signal is unresponsive tothe output of the power converter when the control circuit is in thereduced energy consumption state.
 21. The method of claim 18, furthercomprising generating the drive signal such that an off time of thedrive signal switching period is responsive to the output of the powerconverter.
 22. The method of claim 21, further comprising generating thedrive signal such that an on-time of the drive signal switching periodis responsive to the output of the power converter.
 23. The method ofclaim 18, further comprising operating in a burst mode, wherein thedrive signal is generated with a non-constant switching period byskipping switching cycles.